Rapidtoll CRB-25 Industrial Rebar Bender and Cutter User Guide

CRB-25 Industrial Rebar Bender and Cutter

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Specifications

• Power Supply: 220-240V AC ~50Hz*
• Input Voltage – Single Phase:
  • CRB-25: 1050W – 4.4A
  • CRBC-25: 1050W – 4.4A
  • CRB-32: 1550W – 6.5A
  • CRBC-32A: 2400W – 10A
• Net Weight:
  • CRB-25: 91kg
  • CRBC-25: 136kg
  • CRB-32: 175kg
  • CRBC-32A: 225kg
• Dimensions (cm):
  • CRB-25: 45L x 50W x 44H
  • CRBC-25: 50L x 45W x 79H
  • CRB-32: 60L x 58W x 47H
  • CRBC-32A: 60L x 58W x 98H
• Bending Range:
  • CRB models: 6-25mm**
  • CRBC models: 6-32mm**
• Cutting Range:
  • CRBC-25: 4-25mm**
  • CRBC-32A: 6-32mm**

Product Usage Instructions

Safety

This machine is a high-performance industrial tool. Follow
safety instructions to prevent serious injury or death:

1. Take note of warning signs on the machine.
2. Maintain a clean work area free from obstructions.
3. Ensure the safety guard is installed before operation.
4. Mount the machine on an even surface capable of carrying its
   weight.

Transporting Machine

When transporting the machine:

• Do not lift from certain areas.

• Use a forklift rated for the machine weight and lift via the
  base.

• Ensure the load is balanced before lifting.

Operating Machine

General notes for operating the machine:

• Do not operate bender and cutter simultaneously.

• Ensure the emergency stop button is accessible.

• Set point 1 angle at least 5 degrees higher than point 2
  angle.

• Wait until the bending cycle is completed before starting a new
  cycle.

Pre-use Checks

1. Check the power supply is properly earthed.
2. Inspect the power cord for damage and ensure the plug is
   secure.

Bending Procedure

1. Select the required fixed bending pin and gyre bending pin
   combination.

2. Adjust the block to fit the bar size.

3. If using a pedal switch, securely fasten its cords to the
   machine inputs.

4. Connect to a power source and observe the power indicator
   light.

FAQ

Q: Can this machine be used for commercial rebar

production?

A: No, this machine is not rated for commercial rebar production
purposes. It is for industrial use only.

Q: What should I do if the power indicator light does not turn

on?

A: Check the power supply connection and ensure it is properly
earthed. If the issue persists, contact customer support for
assistance.

Q: How do I transport the machine safely?

A: Use a forklift rated for the machine weight, lift via the
base, and ensure the load is balanced before lifting.

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User’s Guide
RAPIDTOOL Industrial Rebar Benders & Cutters

WARNING: READ ALL SAFETY WARNINGS,
INSTRUCTIONS, ILLUSTRATIONS AND SPECIFICATIONS
PROVIDED WITH THIS POWER TOOL.
Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury. Save all warnings and instructions for future reference.
Machine is not rated and should not be used for commercial rebar production purposes. Do not operate bender and cutter at the same time.
FOR INDUSTRIAL USE ONLY.
Rebar Bender Models
1. Safety
This machine is a high performance, industrial machine. Failure to follow safety instructions may result in serious injury or death.
1. Take note of all warning signs on machine. 2. Keep work area clean and free from obstruction. 3. Ensure safety guard is installed before operation. 4. Mount machine on even surface capable of carrying weight of machine. Machine must be
mounted so supply disconnecting device, actuators, and emergency stop button is at least 600mm above servicing level. Machine should not vibrate on surface during operation. 5. Ensure power supply is properly earthed. 6. Keep body parts well clear of moving parts and protected areas when machine is switched on. 7. Authorized personal protective equipment must be worn when operating machine (minimum requirement – safety glasses (when operating cutter), protective gloves and class 2 hearing protection). 8. Indoor use only – never operate machine in wet or damp conditions. 9. Stand well clear of machine when in use (opposite the direction of bend). 10. Use away from others, particularly children. 11. Ensure power & pedal switch cords are securely fastened prior to switching on machine. 12. Use emergency stop button immediately if issues arise during operation. 13. Only lift via marked locations on base. 14. Never attempt to bend rebar outside of models prescribed diameter range (refer to table in Specifications & Parts section). 15. Do not bend short lengths. 16. Clean machine of loose debris after use. 17. Never attempt to service machine (other than general maintenance procedures outlined in Maintenance section). Contact supplier if issue arises. 18. Only use RAPIDTOOL approved spare parts and accessories with machine. 19. Keep away from sparks and naked flames. 20. Always check power cords for damage and safe placement prior to use. 21. Disconnect machine from power outlet when not in use. 22. Inspect machine before each use. Do not use when quality has been compromised. 23. Do not cover air vents on machine. 24. Store out of reach of children.

2. Transporting Machine

Do not lift here.

Do not lift here.

Forklift from base. Lift via base with forklift rated for machine weight. Ensure load is balanced before lifting.

3. Specifications & Parts

Power Supply: Ensure machine is connected to correct power supply (check machine label to confirm power supply).
Extension Leads: Where possible, connect machine directly to power outlet. If an extension lead is required, ensure lead is under 50m in length. Minimum extension lead diameter are prescribed below:

Extension Lead Length (m) 30m 50m

Min Wire ø (mm²) 2.5 4.0

Machine Specifications

Models

CRB-25 CRBC-25 CRB-32 CRBC-32A

Input Voltage – Single Phase

220-240V AC ~50Hz*

Rated Input Power – Current 220-240V

Bender Cutter

1050W – 4.4A
–

1050W – 4.4A
1550W – 6.5A

2400W – 10A
–

2400W – 10A
3000W – 12.5A

Net Weight

91kg

136kg

175kg

225kg

Dimensions (cm)
Bending Range Cutting Range

45L x 50W x 44H
6-25mm**
–

50L x 45W x 79H
6-25mm
4-25mm

60L x 58W x 47H
6-32mm**
–

60L x 58W x 98H
6-32mm
6-32mm

• Check machine label to determine correct power supply. ** Refer to machine model data sheet for maximum tensile strength/grade.

Machine Parts

Adjustment Block Fixed Bending Pin Gyre Bending Pin

Bend Table
Power Indicator Light

Point 1 Angle Control Dial Point 2 Angle Control Dial Emergency Stop Button

Start Switch

Pedal Switch
Pedal Switch Point 2 Input Pedal Switch Point 1 Input

Note: Location of features on machine face may vary with machine model.

4. Operating Machine
Do not operate bender and cutter at the same time.
General notes: Machine is equipped with an emergency stop button. Ensure pedal switch cords are securely fastened to inputs (if pedal switch required). Always ensure point 1 angle is set at least 5 degrees higher than point 2 angle. Ensure angle control dials are securely fastened. Wait until bending cycle is completed before starting new cycle. If pedal switches are not required, press the start switch to bend to point 1 angle.
Pre-use Checks 1. Check power supply is properly earthed. 2. Check that power cord is undamaged and plug is not loose (also applies for extension leads).
Bending Procedure 1. Secure required fixed bending pin and gyre bending pin combination as per table below. 2. Modify adjustment block to suit required bar size. 3. Securely fasten pedal switch cords to machine inputs (if required). 4. Connect to power source and observe power indicator light on machine face indicating
machine is ready for use. 5. Adjust point 1 and point 2 angle control dials to required angles ensuring point 1 angle is set
at least 5 degrees higher than point 2 angle. Securely fasten angle control dial once required angles are set. 6. Stand well clear of machine (opposite direction of bend). 7. Press the pedal switch connected to pedal switch point 1 input to bend to point 1 angle. Note: Pressing the start switch will also bend to point 1 angle. 8. Press the pedal switch connected to pedal switch point 2 input to bend to point 2 angle. 9. Bender/cutter model also has pedal switch point 3 input to operate cutter (see Additional Instructions for Rebar Cutter section).

CRB-25/CRBC-25
Bar Diameter 12mm 16mm 20mm 24mm
CRB-32/CRBC-32A
Bar Diameter 12mm 16mm 20mm 24mm 28mm 32mm

Max. No. of Bars 4 2 1 1
Max. No. of Bars 5 3 2 1 1 1

CRB-25/CRBC-25
Fixed Bending Pin ø80 ø105

Gyre Bending Pin ø115 ø85

CRB-32/CRBC-32A
Fixed Bending Pin ø80 ø120 ø140

Gyre Bending Pin ø165 ø110 ø75

Note: Refer to RAPIDTOOL specifications where fixed/gyre bending pin diameters provided are not included in tables above.

5. Working Conditions

Do not use or store machine outside of environmental conditions below:

Working Temperature Humidity Storage Temperature Elevation Environment

-10°C – +45°C <90% RH -20°C – +65°C < 100m Interior, waterproof, non-corrosive, non-flammable

6. Maintenance

Always ensure power is disconnected before performing maintenance.
Cleaning: Always wear gloves to protect hands from metal splinters when cleaning. Wipe or brush away all dust and metal filings from Band Table afater use to prevent debris entering the machine (can use compressed air).
Bend Table Bolts: Ensure Bend Table Bolts are tightened before use.
Carbon Brushes: Inspect carbon brushes monthly. Worn brushes will result in power loss and cause irreparable damage to the armature’s commutator. Check brushes immediately if a loss of power or electrical fault is experienced.

Replacing Carbon Brushes: 1. Open the access side panel and locate
the motor housing(s) with black lid. 2. Locate the brush caps on both sides near
the top of the motor housing(s). 3. Open the brush caps with a screwdriver and
remove carbon brushes from the machine. 4. Inspect the carbon brushes and replace
where worn or damaged. 5. Reinstall new carbon brushes and brush caps securely. 6. Replace access side panel.

Brush Caps Motor Housing

Lubrication: Lubricant shall be checked every 2 months for heavy usage or when loss of power is experienced.
Always use approved lubricant with high corrosion and friction resistance properties.
Apply lubricant via grease gun to lubricant hole to ensure lubricant chamber remains full.

Lubricant Hole

Additional Instructions for Rebar Cutter (Rebar Bender/Cutter Model)
Do not operate bender and cutter at the same time.

1. Safety

1. Keep body parts well clear of cutting blocks when machine is switched on. 2. Never attempt to cut rebar outside of models prescribed diameter range (refer to table in
Specifications & Parts section). 3. Do not cut short lengths. 4. Inspect cutter before each use (refer to Maintenance section). Do not use when quality has
been compromised. 5. Beware of ejected objects during the cutting process. Always wear approved safety glasses. 6. Use protective gloves when cleaning machine or handling cutter blocks as edges are very sharp. 7. Do not touch pump housing after use as it will be hot. Wait for machine to cool. 8. Where available, safety guard should be installed. 9. Use Allen Key to loosed and activate Release Valve function when required.
2. Cutter Parts
Note: Safety guard installation – use bolts supplied with safety guard to securely replace existing cutter block bolts, ensuring safety guard covers bar ejection zone.

Cutter Rod

Oil Plug

Cutter Blocks

Safety Guard
U-Shaped Support

Brush Caps

Stopper

Pump Housing

Cutter Block Bolts Release Valve Motor Housing (Specific models only)

Note: Cutter body varies with different models – use as a general guide.

3. Operating Machine
Pre-use Checks: Check condition of cutter blocks and tightness of cutter block bolts (refer to Maintenance section).
Warm Up: In cold weather, warm up cutter by repeating cut cycle for 60 seconds to ensure hydraulic oil reaches proper viscosity.
Stopper Adjustment: Adjustable stopper must be set in correct position dependent on size of rebar. 1. Insert rebar into U-shaped support. 2. Keeping rebar at 90° to machine, screw in stopper until it is just touching the rebar.
Cutting Procedure: 1. Securely fasten pedal switch chord to pedal switch point 3 input. 2. Connect to power source and observe power indicator light on machine face indicating
machine is ready for use. 3. Insert rebar between stopper and front cutter block, making sure it is horizontally seated in
U-shaped support. 4. Press the pedal switch connected to pedal switch point 3 input while cutter rod advances and
fully cuts rebar. 5. Release pedal switch only once rebar has been fully cut to allow cutter rod to retract.
Note: Power will be compromised if hydraulic oil exceeds 70°C. Allow machine to cool before resuming operation.
Note: Do not cut rebar on an angle. Incorrect placement of rebar may cause damage to cutter blocks and/or cutter rod, voiding warranty.
4. Maintenance
Always ensure power is disconnected before performing maintenance.
To access Rebar Cutter: 1. Open the access side panel and locate the rebar cutter with a black cover. 2. Remove the screws to lift cover and access rebar cutter.
Cutter Blocks: Check cutter blocks for damage before each use. If cutter block is damaged, replace block before next use as per following diagram:
Fix longer cutter block bolt pair and washer here

Ensure cutter block with rounded edges installed here

Ensure cutter block with flat edges installed here
Fix shorter cutter block bolt pair and washer here

Check cutter block bolts for tightness before each use. Use protective gloves when handling cutter blocks as edges are very sharp.

Cleaning: Clean machine after each use. Use protective gloves when cleaning to protect hands from metal splinters. Do not use air gun as this may cause dust and metal filings to enter vents. 1. Extend cutter rod and disconnect from power source. 2. Wipe or brush away all dust and metal filings. Pay particular attention to lower half of cutter rod. 3. Connect to power source and press pedal switch to complete cut cycle.
Oil Level Check: Check oil every 2 months or if loss of power apparent in rebar cutter. Hydraulic oil is highly flammable; keep away from sparks and naked flame. In case of ingestion or eye contact, consult a physician immediately. 1. Adjust stopper and make 3-4 cuts, noting exactly the point in which rebar is breaking. 2. Pinch next bit of rebar, stopping just before it breaks. Unplug machine from power source. 3. Turn unit over so oil plug is uppermost (if machine is hot allow to cool down first). 4. Remove oil plug and seal washer (never remove when machine is hot). 5. Check oil is level with bottom of plug hole. If oil is too low, top up with approved ISO VG46 oil. 6. Remove air bubbles – gently tilt cutter lengthways and return to level position. Top up and tilt
cutter in opposite direction. Repeat this process until all air has been extracted. 7. Replace seal washer and oil plug. 8. Connect to power source and completely sever rebar.
Oil Change: Change oil at least once a year or sooner if it appears dirty. 1. Unplug machine from power source. 2. Turn unit over so oil plug is uppermost (if machine is hot allow to cool down first). 3. Remove oil plug and seal washer (never remove when machine is hot). 4. Turn cutter over and drain oil into a suitable receptacle. When oil ceases to drain, tilt machine
to rear to allow oil trapped in piston housing to drain out. When housing is empty, tilt unit in the opposite direction to empty the residue in the pump case. 5. Once all oil has been drained from the machine, turn unit over so oil plug is uppermost. 6. Slowly fill the machine with fresh oil and replace seal washer and oil plug. 7. Connect machine to power source and follow procedure for Oil Level Check.
Note: Dispose of hydraulic oil in accordance with local regulations.
Bolt Tightness: All bolts should be checked for tightness on a weekly basis or after every 500 cuts (whichever comes first).
Carbon Brushes: Inspect carbon brushes on a monthly basis. Worn brushes will result in power loss and cause irreparable damage to the armature’s commutator. Check brushes immediately if a loss of power or electrical fault is experienced.
Replacing Carbon Brushes: 1. Unplug machine from power source. 2. Locate the brush caps on both sides near the back of the motor housing. 3. Open the brush caps with a screwdriver and remove carbon brushes from the machine. 4. Inspect the carbon brushes and replace where worn or damaged. 5. Reinstall new carbon brushes and brush caps securely.

RAPIDTOOL Taren Point, NSW 2229 AUSTRALIA
www.rapidtool.com.au

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